U.S. Patent: 5110378 - Metallic glasses having a combination of high permeability, low coercivity, low ac core loss, low exciting power and high thermal

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United States Patent	*5,110,378*
Hasegawa , et al.	May 5, 1992

Metallic glasses having a combination of high permeability, low coercivity, low ac core loss, low exciting power and high thermal stability

Abstract

Metallic glasses having high permeability, low coercivity, low ac core loss, low exciting power, and high thermal stability are disclosed. The metallic glasses are substantially completely glassy and consist essentially of about 71 to 79 atom percent iron, about 1 to 6 atom percent of at least one member selected from the group consisting of chromium, molybdenum, tungsten, vanadium, niobium, tantalum, titanium, zirconium and hafnium, about 12 to 24 atom percent boron, about 1 to 8 atom percent silicon, 0 to about 2 atom percent carbon, plus incidental impurities, the total of boron, silicon and carbon present ranging from about 18 to 28 atom percent. The alloy is heated treated at a temperature and for a time sufficient to achieve stress relief without inducing precipitation of discrete particles therein. Such a metallic glass alloy is especially suited for use in devices requiring high response to weak magnetic fields, such as ground fault interruptors and current/potential transformers.

Inventors:	Hasegawa; Ryusuke (Morristown, NJ); Fish; Gordon (Lake Hiawatha, NJ)
Assignee:	Allied-Signal Inc. (Morris Township, Morris County, NJ)
Appl. No.:	624485
Filed:	December 6, 1990

Current U.S. Class: 148/304; 420/64; 420/67; 420/117; 420/121; 420/123

Intern'l Class: H01F 001/04

Field of Search: 148/307,304,403 420/64,67,117,121,123

References Cited U.S. Patent Documents

Re29989	May., 1979	Polk et al.	148/403.
3856513	Dec., 1974	Chen et al.	75/123.
4225339	Sep., 1980	Inomata et al.	75/123.
4236946	Dec., 1980	Aboaf et al.	148/31.
4462826	Jul., 1984	Inomata et al.	75/123.
4473413	Sep., 1984	Nathasingh et al.	148/31.

Primary Examiner: Sheehan; John P.
Attorney, Agent or Firm: Hampilos; Gus T.

Parent Case Text

This application is continuation of application Ser. No. 235,725 filed on Aug. 17, 1988 and now abandoned which in turn is a continuation of application Ser. No. 065,099 filed on Jun. 19, 1987 and now abandoned which in turn is a continuation of application Ser. No. 825,963 filed Feb. 5, 1986 and now abandoned which in turn is a continuation of application Ser. No. 594,507 filed on Mar. 29, 1984 and now abandoned which in turn is continuation-in-part of application Ser. No. 497,391 filed on May 23, 1983 and now abandoned.

Claims

What is claimed is:

1. A metallic alloy having a dc coercivity ranging from about 0.6 to about 4.1 A/m and an ac core loss ranging from about 1.4 to about 5.9 mW/kg, at 60 Hz and 0.1 T, said alloy being substantially completely glassy and consisting of about 76 and about 78 atom percent iron, about 2 to about 5 atom percent of at least one of chromium and molybdenum, about 14 to about 19 atom percent boron, about 3 to about 6 atom percent silicon, and 0 to about 1 atom percent carbon, plus impurities, the total of boron, silicon and carbon present ranging from about 18 to about 22 atom percent.

2. The alloy of claim 1 wherein the alloy has an impedance permeability, at 0.5 T and 60 Hz, of at least about 50,690.

3. The alloy of claim 1, said alloy having been heat treated at a temperature of about 380.degree.-415.degree. C. for a period of about 0.25-2 hrs. in the presence of a magnetic field.

4. The alloy of claim 1, wherein the total of boron, silicon and carbon present ranges from about 18 to about 21 atom percent, said alloy having been heat-treated at a temperature of about 340.degree. to about 415.degree. C. for a period of about 0.25-2 hours.

5. The alloy of claim 1 wherein the composition is Fe.sub.76.75 Cr.sub.2 B.sub.16 Si.sub.5 C.sub.0.25.

6. A metallic alloy having a dc coercivity not exceeding 5.4 A/m and an ac core loss, at 0.1 T and 60 Hz, not exceeding 4.6 mW/kg said alloy being substantially completely glassy and having the formula Fe.sub.100-a-b-c Mo.sub.a B.sub.b Si.sub.c, where the subscripts are in atomic percent, "a" is from 0.5 to 3, "b" is from 15 to 24, "c" is from 2 to 8 and the sum of b+c is from 18 to 28.

7. The alloy of claim 6 wherein the ac core loss, at 0.1 T and 60 Hz, is from 1.6 to 4.6 mW/kg and the dc coercivity is from 1.5 to 5.4 A/m.

8. The alloy of claim 6 wherein the composition to Fe.sub.75 Mo.sub.2 B.sub.15 Si.sub.8.

9. The alloy of claim 6 wherein the composition is Fe.sub.77 Mo.sub.3 B.sub.18 Si.sub.2.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a method for enhancing the low frequency magnetic properties of metallic glasses having high permeability, low magnetostriction, low coercivity, low ac core loss, low exciting power and high thermal stability.

2. Description of the Prior Art

As is known, metallic glasses are metastable materials lacking any long range order. X-ray diffraction scans of glassy metal alloys show only a diffuse halo similar to that observed for inorganic oxide glasses.

Metallic glasses (amorphous metal alloys) have been disclosed in U.S. Pat. No. 3,856,513, issued Dec. 24, 1974 to H. S. Chen et al. These alloys include compositions having the formula M.sub.a Y.sub.b Z.sub.c, where M is a metal selected from the group consisting of iron, nickel, cobalt, vanadium and chromium, Y is an element selected from the group consisting of phosphorus, boron and carbon and Z is an element selected from the group consisting of aluminum, silicon, tin, germanium, indium, antimony and beryllium, "a" ranges from about 60 to 90 atom percent, "b" ranges from about 10 to 30 atom percent and "c" ranges from about 0.1 to 15 atom percent. Also disclosed are metallic glass wires having the formula T.sub.i X.sub.j, where T is at least one transition metal and X is an element selected from the group consisting of phosphorus, boron, carbon, aluminum, silicon, tin, germanium, indium, beryllium and antimony, "i" ranges from about 70 to 87 atom percent and "j" ranges from 13 to 30 atom percent. Such materials are conveniently prepared by rapid quenching from the melt using processing techniques that are now well-known in the art.

Metallic glasses are also disclosed in U.S. Pat. No. 4,067,732 issued Jan. 10, 1978. These glassy alloys include compositions having the formula M.sub.a M'.sub.b Cr.sub.c M".sub.d B.sub.e, where M is one iron group element (iron, cobalt and nickel), M' is at least one of the two remaining iron group elements, M" is at least one element of vanadium, manganese, molybdenum, tungsten, niobium and tantalum, B is boron, "a" ranges from about 40 to 85 atom percent, "b" ranges from 0 to about 45 atom percent, "c" and "d" both range from 0 to 20 atom percent and "e" ranges from about 15 to 25 atom percent and "e" ranges from about 15 to 25 atom percent, with the provision that "b", "c" and "d" cannot be zero simultaneously. Such glassy alloys are disclosed as having an unexpected combination of improved ultimate tensile strength, improved hardness and improved thermal stability.

These disclosures also mention unusual or unique magnetic properties for many metallic glasses which fall within the scope of the broad claims. However, metallic glasses possessing a combination of higher permeability, lower magnetostriction, lower coercivity, lower core loss, lower exciting power and higher thermal stability than prior art metallic glasses are required for specific applications such as ground fault interrupters, relay cores, transformers and the like.

SUMMARY OF THE INVENTION

The present invention provides a method of enhancing the magnetic properties of a metallic glass alloy having a combination of high permeability, low magnetostriction, low coercivity, low ac core loss, low exciting power and high thermal stability. The metallic glasses consist essentially of about 71 to 79 atom percent iron, about 0.5 to 6 atom percent of at least one member selected from the group consisting of chromium, molybdenum, tungsten, vanadium, niobium/ tantalum, titanium, zirconium, and hafnium, about 12 to 24 atom percent boron, about 1 to 8 atom percent silicon, 0 to about 2 atom percent carbon, plus incidental impurities, the total of boron, silicon, and carbon present ranging from about 18 to 28 atom percent. The method comprises the step of heat-treating the metallic glass alloy for a time and at a temperature sufficient to achieve stress relief without inducing precipitation of discrete particles therein and at least cooling the alloy in the presence of an applied magnetic field.

Metallic glass alloys treated in accordance with the method of this invention are especially suitable for use in devices requiring high response to weak magnetic fields, such as ground fault interrupters and current/potential transformers.

DETAILED DESCRIPTION OF THE INVENTION

Heat treatment of the metallic glass alloys of the invention enhances the magnetic properties thereof. More specifically, upon heat treatment in accordance with the invention, the metallic glass alloys evidence a superior combination of the following thermal and magnetic properties: (i) high maximum permeability (e.g. a maximum of about 250,000-300,000 at 60 Hz), low magnetostriction (about 12-24 ppm), low coercivity (about 0.25-2 A/m), low ac core loss (about 1.5-3 mW/kg at 60 Hz and 0.1 T), low exciting power (1.7-5 mVA/kg) and high thermal stability (fist crystallization temperature of about 475.degree.-600.degree. C.). The alloys consist essentially of about 71 to 79 atom percent iron, about 0.5 to 6 atom percent of at least one member selected from the group consisting of chromium, molybdenum, tungsten, vanadium, niobium, tantalum, titanium, zirconium, and hafnium, about 12 to 24 atom percent boron, about 1 to 8 atom percent silicon, 0 to about 2 atom percent carbon, plus incidental impurities, the total of boron, silicon, and carbon present ranging from about 18 to 28 atom percent. The alloys of the present invention are substantially completely glassy, that is to say, they are at least about 95% amorphous, preferably at least about 97% amorphous, and, most preferably, 100% amorphous as determined by transmission electron microscopy and X-ray diffraction. The best magnetic properties are obtained in alloys having the greatest volume percent of amorphous material. The heat-treating step comprises the steps of (a) heating the alloy to a temperature at least that sufficient to achieve stress relief without inducing precipitation of discrete particles therein; (b) cooling the alloy to a temperature below about 200.degree. C.; and (c) applying a magnetic field to the alloy during at least the cooling step. The cooling step is typically carried out at a cooling rate of about -0.5.degree. C./min to -100.degree. C./min and preferably at a rate of about -0.5.degree. C./min to -20.degree. C./min. However, faster cooling rates of at least about -1000.degree. C./min, such as are achieved by quenching the alloy in a liquid medium selected from the group consisting of water, brine and oil, can also be used. The highest permeability is obtained in an alloy which is cooled slowly, for example, at a rate of between about -0.5.degree. C./min and -10.degree. C./min.

A heat treatment carried out in the absence of an applied magnetic field results in insufficient improvement of the properties of permeability, core loss and coercivity.

It is generally found that the process of forming metallic glass alloys results in cast-in stresses. Further stresses may be introduced by the process of fabricating cores from metallic glass alloys. Hence it is preferred that the metallic glass alloy be heated to a temperature and held for a time sufficient to relieve these stresses. Furthermore, during that heat treatment, the presence of a magnetic field enhances the formation of magnetic anisotropy in the direction along which the field is applied. The field is especially effective when the alloy is at a temperature which is near the Curie temperature or up to 50.degree. C. below and which is high enough to allow atomic diffusion or rearrangement. Thus it is especially preferred that the alloy be annealed at a temperature above the Curie temperature and that it be cooled through the Curie temperature and to a temperature at least 50.degree. C. therebelow in the presence of applied field. Below about 200.degree. C., the atomic mobility is too low for the field to be of particular effectiveness.

The resulting material is especially suited for application in magnetic devices operating at line frequencies (50-400 Hz).

The magnetic cores of the invention are preferably fabricated by first forming the metallic glass into the desired final shape (e.g., a core) and then subjecting the core to the appropriate heat treatment described herein. The magnetic fields are applied in the longitudinal or transverse directions, defined, respectively, as the direction along which the core is magnetically excited during operation and the direction perpendicular to that of magnetic excitation during operation. Most preferably, the core is a wound toroid in which a continuous ribbon of metallic glass is wound upon itself or upon a supporting bobbin. For such a core, the longitudinal direction is the circumferential direction in which the ribbon is wound and the transverse direction is parallel to the axis of the toroid. A longitudinal magnetic field (H.parallel.) is conveniently applied to a toroid either by passing a suitable electric current through a set of toroidally wound windings or by passing a suitable current through at least one conductor directed through the center of, and parallel to the axis of, the toroid. A transverse magnetic field (H.perp.) is conveniently applied by placing the toroid coaxially between the poles either of permanent magnets or of an electromagnet or by placing the toroid coaxially inside a solenoid energized by a suitable electric current.

The temperature (T.sub.a) and holding time (t.sub.a) of the preferred heat treatment of the metallic glasses of the present invention are dependent on the composition of the alloy. When the total of boron, silicon and carbon present is about 18-21 atom percent and the total of the elements of the groups IVA, VA, and VIA (i.e., Mo, Cr, Ti, Ta, W, Hf, Zr, Nb, and V) present is about 1-2 atom percent, then T.sub.a is about 340.degree.-400.degree. C. and t.sub.a is 0.25-1 h; when the total of boron, silicon, and carbon present is about 18-21 atom percent and the total of the elements of groups IVA, VA, and VIA present is about 3-6 atom percent, then T.sub.a is about 340.degree.-415.degree. C. and T.sub.a is 0.25-2 h; when the total of boron, silicon, and carbon present is about 22-28, then T.sub.a is about 340.degree.-415.degree. C. ant t.sub.a is 0.25-2 h.

The method of enhancing the magnetic properties of the alloys of the present invention is further characterized by the choice of two different directions of the magnetic field applied during the heat treatment. The direction is chosen on the basis of the desired final properties.

The first preferred method comprises a heat treatment in a longitudinal field whose preferred strength ranges from about 200 to 4000 A/m. The temperature and duration of anneal are chosen to be adequate to achieve stress relief without inducing precipitation of discrete particles in the alloy. The resulting material is characterized by a square hysteresis loop with low coercivity and high permeability, especially for excitation at frequencies of 50-400 Hz. Preferably, the squareness ratio, defined as the ratio of remanent to saturation induction, is at least 0.90, the maximum permeability measured at 60 Hz is at least 250,000, and more preferably, at least 300,000, and the coercivity is less than 1 A/m, preferably less than 0.75 A/m, and most preferably less than 0.5 A/m. Magnetic cores fabricated with such annealed material are especially suited for devices such as ground fault interrupters which detect the presence of low ac magnetic fields. The high magnetic permeability renders such devices more sensitive.

The second preferred method is a heat treatment in the presence of a transverse field, and, optionally, in the presence of a mixed magnetic field having a first component applied in the transverse direction and a second component applied in the longitudinal direction. For heat treatment in the presence of a transverse field, the field strength is typically about 2400 to 16,000 A/m. For heat treatment in the presence of a mixed field, the first component has a strength of about 4,000 to 16,000 A/m and the second component has a strength of about 0 to about 2400 A/m. The duration and temperature of heat treatment are chosen as in the first method. The resulting material is characterized by low dc coercivity, low squareness ratio, and high permeability over a wide range of applied field, Preferably, the coercivity is less than 0.75 A/m and, within a range of magnetic fields applied at 60 Hz whose maximum and minimum peak amplitudes are in a ratio of at least 25:1, the impedance permeability is at least 40,000 and varies by no more than a factor of three. That is, the maximum and minimum values of the impedance permeability have a ratio not exceeding about 3:1. Magnetic cores fabricated with such annealed material are especially suited for applications such as current/potential transformers which measure the intensity of an ac field. The near constant permeability allows a device such as a current/potential transformer to provide a linear output over a wide range of applied fields. The high permeability renders a device more sensitive at lower applied fields.

Alloys heat-treated with applied transverse field in accordance with present invention have a further advantage in their higher permeability under unipolar magnetic excitation than that of heat-treated alloys of the prior art. The magnetic permeability measured under unipolar excitation (e.g., full-wave or half-wave rectified ac current) is generally much lower than that measured under bipolar excitation (e.g., sinusoidal current), since the maximum unipolar flux swing is limited to the difference between saturation and remanent induction measured at the desired frequency, compared to twice the saturation induction for bipolar excitation. Furthermore, the BH loop of prior art materials has higher squareness ratio when measured at line frequencies than at dc, leading to a further reduction in the difference between saturation and remanence and, hence, lower unipolar permeability. In contrast, the heat-treated alloys of the present invention show acceptably high unipolar flux swing and permeability. For example, Table I compares permeabilities of Fe.sub.76.5 Cr.sub.2 B.sub.16 Si.sub.5 C.sub.0.25 annealed with the method of present invention and Fe.sub.78 B.sub.13 Si.sub.9 annealed by the prior art method, demonstrating the superiority of the present invention.

                  TABLE I
    ______________________________________
    Permeabilities of (A) Fe.sub.76.5 Cr.sub.2 B.sub.16 Si.sub.5 C.sub.0.25
    metallic
    glass annealed at 400.degree. C. for 1 h with H.parallel. = 1600 A/m and
    H.perp. = 8000 A/m and (B) prior art Fe.sub.78 B.sub.13 Si.sub.9 annealed
    with
    H.parallel. = 800 A/m at 400.degree. C. for 2 h and excited with
    sinusoidal
    (bipolar) and full-wave rectified sinusoidal (unipolar)
    60 Hz current to the maximum field H.sub.m shown.
                 Impedance Permeability
    H.sub.m (A/m)  A         B
    ______________________________________
    (Unipolar)
    0.16            27,000    4,645
    0.40            45,370    2,312
    0.80            71,900    2,934
    1.60           106,020    6,868
    2.40           106,550    8,282
    2.80           --         7,544
    3.20           106,060   --
    3.60           --         7,182
    4.00           101,420   --
    4.80            92,324    6,290
    (Bipolar)
    0.16            19,090    1,295
    0.40            66,070    3,077
    0.80           107,670    19,040
    1.60           129,712    66,410
    2.40           126,670   157,490
    3.20           117,890   167,370
    4.00           109,490   143,360
    4.80           102,230   121,840
    ______________________________________

Metallic glass alloys consisting essentially of about 68 to 78 atom percent iron, about 2 to 5 of at least one number selected from the group consisting of chromium and molybdenum, about 14 to 19 atom percent boron, about 3 to 6 atom percent silicon, from 0 to 1 atom percent carbon, the total of boron, silicon and carbon present ranging from about 18 to 22, when heat treated at a temperature of 380.degree.-415.degree. C. for a period of 0.25-2 hours in the presence of an applied magnetic field, produce a particularly outstanding combination of high permeability, low coercivity, low ac core loss, low exciting power and high thermal stability. These properties make the alloys especially suited for use in ground fault interrupters and current/potential transformers. Accordingly such alloys are preferred.

Saturation magnetostriction is the change in the length of a magnetic material under the influence of a saturating magnetic field. A lower saturation magnetostriction renders a material less sensitive to externally applied stresses. Magnetostriction is usually discussed in terms of the ratio of the change in length to the original length, and is given in parts per million (ppm). Prior art iron rich metallic glasses evidence saturation magnetostrictions of about 30 ppm as do metallic glasses without the presence of any of the elements belonging to the IVA, VA, and VIA columns of the periodic table, such as molybdenum. For example, a prior art iron rich metallic glass designated for use in line frequency applications and having the composition Fe.sub.78 B.sub.13 Si.sub.9 has a saturation magnetostriction of about 30 ppm. In contrast, a metallic glass of the invention having the composition Fe.sub.76.75 Cr.sub.2 B.sub.16 Si.sub.5 C.sub.0.25 has a saturation magnetostriction of about 20 ppm.

It is well-known as a guiding principle in the art of magnetic materials that reduction of magnetostriction by appropriate selection of alloy composition yields a product with enhanced magnetic properties, such as higher permeability and reduced core loss. See, e.g., Richard M. Bozorth, Ferromagnetism (New York: D. Van Nostrand, 1951), pp. 626-627. The alloys of the present invention have magnetic properties for line frequency (50-400 Hz) applications that are far better than would be expected, given that their saturation magnetostrictions (.lambda..sub.s) are in the range of 18-22 ppm. Their line frequency properties are comparable to those of the FeNi-based glasses containing nearly equal amounts of Fe and Ni (.lambda..sub.2=.sup..congruent. 8-12 ppm) and crystalline permalloys containing about 80 percent Ni (.lambda..sub.s=.sup..congruent. 0)

The prior art FeNi- and Co-based amorphous alloys and crystalline permalloys require the presence of a substantial fraction of either Ni or Co to achieve the desired properties. The relatively higher raw material cost of Ni and Co compared to that of Fe therefore renders these prior art amorphous and crystalline alloys inferior for application to the heat-treated alloys of the present invention.

Ac core loss is that energy loss dissipated as heat. It is the hysteresis in an ac field and is measured by the area of a B-H loop for low frequencies (less than about 1 kHz) and from the complex input power in the exciting coil for high frequencies (about 1 kHz to 1 MHz). The major portion of the ac core loss at high frequencies arises from the eddy current generated during flux change. However, a smaller hysteresis loss and hence a smaller coercivity is desirable especially at line frequency. A lower core loss renders a material more useful in certain applications such as tape recorder heads and transformers. Core loss is discussed in units of watts/kg at a specified maximum induction level and at a specified frequency. For example, a prior art heat-treated metallic glass having the composition Fe.sub.40 Ni.sub.36 Mo.sub.4 B.sub.20 has an ac core loss of 0.07 watts/kg at an induction of 0.1 Tesla and a frequency of 1 kHz, while a metallic glass having the composition Fe.sub.76 Mo.sub.4 B.sub.20 has an ac core loss of 0.08 watts/kg at an induction of 0.1 Tesla and the same frequency. In contrast, a metallic glass alloy of the invention having the composition Fe.sub.76.75 Cr.sub.2 B.sub.16 Si.sub.5 Co.sub.0.25 has an ac core loss of 0.06 watts/kg at an induction of 0.1 Tesla and the same frequency.

Exciting power is a measure of power required to maintain a certain flux density in a magnetic material. It is desirable that a magnetic material to be used in magnetic devices have an exciting power as low as possible. Exciting power (P.sub.e) is related to the above-mentioned core loss (L) through the relationship L=P.sub.e sin .delta. where .delta. is the phase shift between the exciting field and the resultant induction. The phase shift is also related to the magnetostriction in such a way that a lower magnetostriction value leads to a lower phase shift. It is then advantageous to have the magnetostriction value as low as possible. As mentioned earlier, prior art iron-rich metallic glasses such as Fe.sub.78 B.sub.13 Si.sub.9 have the magnetostriction value near 30 ppm, in contrast to the magnetostriction value of about 20 ppm of the metallic glasses of the present invention.

Magnetic permeability is the ratio of induction to applied magnetic field. A higher permeability renders a material more useful in certain applications such as ground fault interrupters, due to the increased sensitivity. A particular measure of permeability under ac excitation is impedance permeability, defined to be the ratio of the apparent maximum induction to the apparent maximum magnetic field, as determined for a magnetic core from the root mean square (rms) value of the voltage induced in a set of secondary windings and the rms value of exciting current in a set of primary windings, respectively. Especially noted is the fact that a heat-treated Fe.sub.76.75 Cr.sub.2 B.sub.16 Si.sub.5 C.sub.0.25 metallic glass has an impedance permeability of about 300,000 while the best heat-treated prior art Fe.sub.78 B.sub.13 Si.sub.9 metallic glass has an impedance permeability of 100,000 at 60 Hz and at the induction level of 0.6 Tesla.

In applicant's application Ser. No. 497,391 filed May 23, 1983, it is disclosed and claimed that the high frequency (f>1 kHz) magnetic properties of certain iron-based metallic glasses are enhanced by a heat treatment at a temperature and for a time sufficient to induce precipitation of discrete particles into the amorphous matrix. Such a heat treatment is distinguished from the heat treatment of the present invention in that the line frequency properties of metallic glasses heat treated according to the method of the present invention are superior to those of glasses heat treated according to the method of the prior inventions. Conversely, the high frequency properties of metallic glasses heat-treated according to the method of the prior invention are superior. Table II shows representative properties of a metallic glass having the composition Fe.sub.76.75 Cr.sub.2 B.sub.16 Si.sub.5 C.sub.0.25 heat-treated according to the methods of the present and the prior inventions.

                                      TABLE II
    __________________________________________________________________________
    Magnetic properties of toroids fabricated with
    Fe.sub.76.75 Cr.sub.2 B.sub.16 Si.sub.5 C.sub.0.25 metallic glass and
    heat-treated by
    the method of the present invention (A) and by the
    method of Application Serial Number 497,391 (B). Sample
    A was treated at 400.degree. C. for 1 h in the presence of an
    800 A/m longitudinal field. Sample B was treated at
    440.degree. C. for 2.0 h in the same field. Core loss (L),
    exciting power (P.sub.e) and impedance permeability .mu..sub.z were
    measured at f = 60 Hz/B.sub.m = 0.1 Tesla and at f = 50k Hz/Bm = 0.1
    Tesla.
    H.sub.c
          60 Hz properties 50k Hz properties
    (A/m) L (mW/kg)
                P.sub.e (mVA/kg)
                       .mu..sub.z
                           L (W/kg)
                                 P.sub.e (VA/kg)
                                       .mu..sub.z
    __________________________________________________________________________
    A.
      0.87
          2.4   2.5    86,860
                           66.6  72.8  2365
    B.
      4.9 2.8   5.9    37,120
                           27.0  39.0  4415
    __________________________________________________________________________

As is well known in the art (see, e.g., Donald G. Fink and H. Wayne Beaty, Standard Handbook for Electrical Engineers (New York: McGraw Hill, 1978) pp 3-23-3-24), current/potential transformers are devices used to monitor currents or voltages either where the currents or voltages are too large for conventional meters or where it is desired to have the measuring instrument electrically isolated from the circuit being tested. The transformer typically comprises a toroidal core with primary and secondary windings.

For monitoring current, the primary consists of at most a few turns connected in series with the load and the secondary has many turns, frequently more than 200. For monitoring potential, the primary has many turns and is connected in parallel with the load and the secondary has few turns. The voltage induced in the secondary is proportional to the primary current or voltage, as appropriate.

It has long been recognized in the art (see, e.g., H. Pender, W. A. Del Mar, and K. McIlwain, Electrical Engineers' Handbook: Electrical Power (New York: John Wiley, 1941), pp. 5-55-5-60.) that smaller, more efficient, and more accurate current/potential transformers could be built by employing magnetic cores having higher permeability, lower losses, lower phase shift and lower exciting power. Yet up to the time of the present invention, metallic glass cores having the requisite combination of properties, e.g. high maximum permeability, low magnetostriction, low ac core loss, low exciting power and high thermal stability, have not been available. It has been discovered that cores comprised of metallic glass alloys annealed in accordance with the present invention have this requisite combination of properties. Hence, current/potential transformers employing the magnetic cores of the invention are superior to transformers employing prior art cores.

As is well known in the art, e.g., U.S. Pat. No. 4,363,103 issued Oct. 5, 1982 to G. A. Whitlow, a ground fault interrupter is an electrical protective device which interrupts the flow of electrical supply current to a circuit upon occurrence of a ground fault, i.e., an imbalance between the current flowing from the electrical power distribution system into a load and the current returning to the distribution system from the other side of the load. Such an imbalance is indicative of a ground fault current flowing from some point in the load to ground by an alternate path. Such a leakage current is potentially hazardous, as in the case of a leakage current flowing through the body of the user of a defective appliance. Ground fault interruption means are now required by electrical codes for electrical service in certain hazardous locations, e.g., outlets in garages, bathroom, and outdoors.

A ground fault interrupter frequently comprises a differential current transformer with a toroidal magnetic core. The primary of the transformer has separate windings through which the supply current and the return current, respectively, pass. The windings are disposed in such a manner that when the supply and return currents are equal, i.e., no ground fault exists, the magnetic fields produced by the separate windings cancel. When a ground fault occurs, the cancellation is no longer exact. The resulting ac magnetic field induces a voltage in a multiturn secondary winding which is used to activate means for interrupting the flow of supply current.

The sensitivity of a ground fault interrupter is determined by the permeability of the magnetic core. That is, for a given size of core, the ground fault current trip level decreases as permeability increases. Alternatively, the core size needed for a ground fault interrupter designed to trip at a given ground fault current decreases as the permeability of the core increases. Hence, the high permeability alloys of the present invention are highly preferred for application in ground fault interrupters. Devices comprising differential current transformers with the toroidal magnetic cores of the invention have lower ground fault current trip levels and/or smaller size than devices employing prior art cores.

EXAMPLES

Example 1

Fe-Mo-B-Si

Ribbons having compositions given by Fe.sub.100-a-b-c-a Mo.sub.a B.sub.b Si.sub.c and having dimensions about 0.5 to 1 cm wide and about 25 to 50 .mu.m thick were formed by squirting a melt of the particular composition through an orifice by an overpressure of argon onto a rapidly rotating copper chill wheel (surface speed about 3000 to 6000 ft/min.). Magnetic cores were formed by winding the ribbon thus produced onto toroidal ceramic bobbins and were heat-treated in a tube furnace. Longitudinal magnetic fields were produced by passing the requisite electric current through a set of copper windings applied to the toroid. Transverse magnetic fields were produced either by placing the toroids axially between the poles of two permanent magnets or by placing the toroid coaxially within a solenoid carrying the requisite electric current.

Impedance permeability, magnetostriction, core loss, magnetization and coercive field were measured by conventional techniques employing B-H loops, metallic strain gauges and vibrating sample magnetometer. Curie temperature and crystallization temperature were measured, respectively, by an induction method and by differential scanning calorimetry. The measured values of room temperature saturation induction, Curie temperature, room temperature saturation magnetostriction and the first crystallization temperature are summarized in Table III below.

                  TABLE III
    ______________________________________
    Examples of basic physical and magnetic properties
    of Fe--Mo--B--Si amorphous alloys. .theta..sub.f and T.sub.x1 are ferro-
    magnetic Curie and first crystallization temperatures,
    respectively. B.sub.s and .lambda..sub.s are the room temperature satu-
    ration induction and saturation magnetostriction,
    respectively. .rho. is the mass density.
    Composition (at. %)
                  .theta..sub.f
                         B.sub.s
                                .rho.  .lambda.
                                              T.sub.x1
    Fe   Mo      B     Si   (.degree.C.)
                                 (T)  (g/cm.sup.3)
                                             (10.sup.-6)
                                                    (.degree.C.)
    ______________________________________
    79   2       17    2    299  1.35 7.47   21.9   509
    79   2       15    4    318  1.42 7.43   24.3   517
    79   2       13    6    300  1.36 7.39   24.4   511
    77   2       19    2    319  1.41 7.47   22.6   522
    77   2       17    4    352  1.41 7.43   25.4   532
    77   2       15    6    335  1.38 7.37   26.2   548
    75   2       21    2    357  1.39 7.48   21.4   538
    75   2       19    4    352  1.36 7.37   21.7   552
    75   2       17    6    355  1.38 7.48   22.9   561
    78   3       17    2    256  1.30 7.61   19.0   520
    78   3       15    4    282  1.35 7.51   21.3   524
    78   3       13    6    258  1.27 7.43   18.9   519
    76   3       19    2    283  1.26 7.42   18.2   534
    76   3       17    4    318  1.34 7.37   22.7   539
    76   3       15    6    287  1.29 7.40   21.4   552
    74   3       21    2    326  1.29 7.45   19.3   550
    74   3       19    4    312  1.28 7.40   19.1   560
    74   3       17    6    314  1.28 --     19.3   565
    71   1       24    4    433  1.42 --     21.3   561
    72   6       18    4    234  1.07 7.46   13.0   569
    72   4       20    4    400  1.41 --     25.1   563
    74   2       20    4    370  1.33 7.40   23.3   601
    73   3       20    4    379  1.33 --     20.6   541
    77   2       13    8    328  1.34 --     21.8   545
    75   2       15    8    353  1.41 --     23.7   574
    71   3       20    6    372  1.38 --     20.0   583
    71   3       18    8    421  1.44 --     17.8   579
    77.5 1.5     16    5    359  1.45 --     26.6   536
    77   2       20    1    329  1.40 --     23.20  518
    78.5 0.5     16    5    395  1.46 --     24.4   525
    ______________________________________

The magnetic properties of these glassy alloys after annealing in a longitudinal applied field are presented in Table IV.

The presence of molybdenum is seen to increase the permeability and the crystallization temperature and to lower the ac core loss, exciting power and magnetostriction. The combination of these properties make these compositions suitable for line frequency devices such as ground fault interrupters and current transformers.

                                      TABLE IV
    __________________________________________________________________________
    Examples of 60 Hz magnetic properties of
    Fe.sub.100-a-b-c Mo.sub.a B.sub.b Si.sub.c metallic glasses. Samples
    were
    heat-treated at a temperature T.sub.a for a holding time
    t.sub.a = 1 h in the presence of an 800 A/m longitudinal
    field. Values of the dc remanent induction B.sub.r, dc
    coercivity, H.sub.c, and 60 Hz impedance permeability .mu..sub.z at
    maximum induction B.sub.m = 0.1 and 0.5 Tesla are shown.
    Composition (at. %)     L (mW/kg,
                                   .mu..sub.z
    Fe Mo B Si
              T.sub.a (.degree.C.)
                   H.sub.c (A/m)
                        B.sub.r (T)
                            B.sub.m = 0.1 T)
                                   0.1 T
                                       0.5 T
    __________________________________________________________________________
    77 3  18
            2 380  1.7  0.77
                            2.5    67,190
                                       174,480
    78 2  18
            2 380  2.5  1.05
                            4.0    45,020
                                       129,300
    77 3  16
            4 400  2.7  0.59
                            2.6    43,340
                                        81,410
    79 2  17
            2 380  2.7  0.74
                            2.9    43,680
                                       100,090
    79 2  15
            4 380  2.0  1.01
                            3.0    56,080
                                       151,490
    79 2  13
            6 380  2.2  0.79
                            3.4    50,110
                                       120,800
    77 2  19
            2 380  1.8  0.78
                            3.2    54,830
                                       126,150
    77 2  17
            4 400  2.8  0.90
                            3.7    42,050
                                       113,410
    77 2  15
            6 400  3.8  0.56
                            2.7    37,170
                                        51,714
    75 2  21
            2 400  2.4  0.79
                            3.8    45,990
                                       101,060
    75 2  19
            4 400  3.9  0.58
                            2.9    31,230
                                        51,160
    75 2  17
            6 400  5.4  0.40
                            3.6    24,280
                                        31,720
    78 3  17
            2 400  3.6  0.20
                            1.6    17,440
                                        14,812
    78 3  15
            4 400  3.6  0.54
                            2.4    37,200
                                        50,690
    78 3  13
            6 400  2.0  0.73
                            2.7    54,740
                                       134,370
    76 3  19
            2 400  2.2  0.51
                            2.6    51,160
                                        60,430
    76 3  17
            4 380  3.4  0.76
                            3.7    36,250
                                        90,930
    74 3  21
            2 400  3.2  0.55
                            3.1    39,740
                                        49,750
    74 3  19
            4 400  2.9  0.52
                            3.2    40,600
                                       106,380
    74 3  17
            6 400  1.7  0.67
                            2.6    61,170
                                       114,300
    71 1  24
            4 400  2.5  0.84
                            4.2    44,870
                                       129,274
    78.5
       0.5
          16
            5 400  2.2  1.22
                            4.6    44,420
                                       139,660
    75 2  15
            8 400  1.5  0.74
                            2.0    79,570
                                       177,620
    __________________________________________________________________________

Example 2

Fe-Cr-B-Si System

Ribbons having compositions given by Fe.sub.100-a-b-c Cr.sub.a -B.sub.b -Si.sub.c and having dimensions about 0.5-1 cm wide and about 25 to 50 .mu.m thick were formed as in Example 1.

The magnetic and thermal data are summarized in Table V below. The magnetic properties of these glassy alloys after annealing are presented in Table VI.

The line frequency magnetic properties of these metallic glasses are comparable to those containing molybdenum (Example 1).

A combination of low ac core loss and high impedance permeability at line frequency is achieved in the metallic glasses of the present invention. The thermal stability is also shown to be excellent as evidenced by high crystallization temperature. These improved combination of properties of the metallic glasses of the present invention renders these compositions suitable for line frequency magnetic devices such as ground fault interrupters, current/potential transformers and the like.

                  TABLE V
    ______________________________________
    Examples of basic physical and magnetic properties
    of Fe--Cr--B--Si amorphous alloys. .theta..sub.f and T.sub.x1 are the
    fer-
    romagnetic Curie and first crystallization temperatures,
    respectively. B.sub.s and .lambda..sub.s are the room temperature satu-
    ration induction and saturation magnetostriction,
    respectively. .rho. is the mass density.
    Composition (at. %)
                  .theta..sub.f
                         B.sub.s
                                .rho.  .lambda..sub.s
                                              T.sub.x1
    Fe   Cr     B      Si   (.degree.C.)
                                 (T)  (g/cm.sup.3)
                                             (10.sup.-6)
                                                    (.degree.C.)
    ______________________________________
    71   1      24     4    444  1.41 --     15.8   537
    79   2      17     2    309  1.44 7.46   23.8   494
    79   2      15     4    315  1.44 --     26.6   503
    77   2      19     2    341  1.42 --     24.5   499
    77   2      17     4    344  1.43 7.33   26.4   514
    75   2      21     2    371  1.42 --     14.5   506
    75   2      19     4    372  1.40 7.36   21.4   534
    78   3      17     2    283  1.33 7.37   19.8   496
    78   3      13     6    297  1.32 7.30   20.3   497
    78   3      15     4    289  1.33 --     20.9   504
    76   3      19     2    314  1.35 --     22.2   500
    76   3      17     4    315  1.33 7.40   20.0   518
    74   3      21     2    343  1.32 7.25   23.0   506
    74   3      19     4    342  1.32 --     22.4   538
    72   6      18     4    251  1.09 --     11.1   534
    72   4      20     4    313  1.24 --     12.2   599
    74   2      20     4    386  1.40 --     11.1   545
    73   3      20     4    362  1.33 --     17.9   547
    77   2      13     8    400  1.52 --     32.6   531
    71   3      20     6    355  1.27 --     20.3   552
    71   3      18     8    367  1.31 7.09   18.6   568
    75   2      15     8    368  1.40 7.58   15.4   553
    77.5 1.5    16     5    360  1.48 --     28.8   520
    77   2      15.8   5.2  360  1.40 --     24.0   523
    75   2      17.8   5.2  369  1.40 --     26.6   536
    76   3      15.8   5.2  323  1.33 7.23   23.5   526
    74   3      17.8   5.2  346  1.30 --     23.4   541
    78.5 0.5    16     5    395  1.35 --     24.9   520
    ______________________________________


                                  TABLE VI
    __________________________________________________________________________
    Examples of 60 Hz magnetic properties of
    Fe.sub.100-a-b- Cr.sub.a B.sub.b Si.sub.c metallic glasses. Samples were
    heat-
    treated at a temperature T.sub.a for a holding time t.sub.a = 1 h in
    the presence of an 800 A/m longitudinal field. Values
    of the dc remanent induction B.sub.r, dc coercivity H.sub.c, and
    60 Hz impedance permeability .mu..sub.z at maximum inductions of
    0.1 and 0.5 Tesla are shown.
    Composition (at. %)     L (mW/kg,
                                   .mu..sub.z
    Fe Cr B Si
              T.sub.a (.degree.C.)
                   H.sub.c (A/m)
                        B.sub.r (T)
                            B/.sub.m = 0.1 T)
                                   B/.sub.m = 0.1 T
                                          0.5 T
    __________________________________________________________________________
    79 2  17
            2 380  3.2  0.81
                            5.4    30,848  89,720
    79 2  15
            2 380  3.4  1.14
                            5.5    35,220  86,090
    79 2  13
            6 380  2.5  1.06
                            5.1    37,000 115,970
    77 2  19
            2 380  2.1  1.02
                            3.7    47,990 144,810
    77 2  17
            2 400  1.5  0.94
                            2.9    66,000 165,080
    77 2  15
            6 400  2.7  0.98
                            4.1    41,890 120,860
    75 2  21
            2 400  1.5  0.90
                            2.6    69,380 166,420
    75 2  17
            6 400  1.1  0.90
                            2.3    83,120 192,870
    78 3  17
            2 400  3.6  0.91
                            5.5    28,870  95,530
    78 3  15
            4 400  4.1  0.95
                            5.9    27,740  90,011
    78 3  13
            6 400  3.1  1.07
                            5.0    34,580 113,040
    76 3  19
            2 400  1.8  0.92
                            3.6    52,150 149,310
    76 3  17
            4 400  1.7  1.08
                            3.3    59,480 160,100
    76 3  15
            6 400  2.1  0.87
                            4.0    46,680 126,590
    74 3  21
            2 400  2.1  0.87
                            3.6    47,350 129,440
    74 3  19
            4 400  1.1  0.85
                            2.3    81,010 190,312
    74 3  17
            6 400  1.5  0.89
                            3.0    61,550 154,080
    78.5
       0.5
          16
            5 400  1.7  1.02
                            3.2    61,540 172,910
    __________________________________________________________________________

Example 3

Fe-M-B-Si System

Ribbons having composition given by Fe.sub.100-a-b-c M.sub.a -B.sub.b -Si.sub.c, where M is at least one of tungsten, vanadium, niobium, tantalum, titanium, zirconium, and hafnium, and having dimensions about 0.5-1 cm wide and about 25 to 50 .mu.m thick were formed as in Example 1.

The magnetic and thermal data are summarized in Table VII below. The magnetic properties of these glassy alloys after annealing are presented in Table VIII.

The line frequency magnetic properties of these metallic glasses are comparable to those containing molybdenum (Example 1).

A composition of low ac core loss and high impedance permeability at line frequency is achieved in the metallic glasses of the present invention. The thermal stability is also shown to be excellent as evidenced by high crystallization temperature. The improved combination of properties of the metallic glasses of the present invention renders these compositions suitable for line frequency magnetic devices such as ground fault interrupters, current/potential transformers and the like.

                  TABLE VII
    ______________________________________
    Examples of basic physical and magnetic properties
    of Fe--M--B--Si amorphous alloys, where M.dbd.Nb, V, W, Zr, Ti,
    Hf, or Ta. .theta..sub.f and T.sub.x1 are the ferromagnetic and first
    crystallization temperatures, respectively, B.sub.s and .lambda..sub.s
    are the room temperature saturation induction and satu-
    ration magnetostriction, respectively, .rho. is the mass
    density.
                                              T.sub.x1
    Composition
               .theta..sub.f (.degree.C.)
                       B.sub.s (T)
                               .rho. (g/cm.sup.3)
                                       .lambda. (10.sup.-6)
                                              (.degree.C.)
    ______________________________________
    Fe.sub.73 Nb.sub.3 B.sub.20 Si.sub.4
               320     1.25    7.37    17.4   586
    Fe.sub.73 V.sub.3 B.sub.20 Si.sub.4
               350     1.34    --      20.1   560
    Fe.sub.78.5 W.sub.1.5 B.sub.17 Si.sub.3
               345     1.39    --      22.0   521
    Fe.sub.78.5 Zr.sub.1.5 B.sub.17 Si.sub.3
               356     1.52    7.44    26.1   533
    Fe.sub.78.5 Ti.sub.1.5 B.sub.17 Si.sub.3
               355     1.42    --      29.3   524
    Fe.sub.73 Ti.sub.3 B.sub.20 Si.sub.4
               381     1.48    --      25.6   535
    Fe.sub.78.5 Hf.sub.1.5 B.sub.17 Si.sub.3
               355     1.37    --      24.8   543
    Fe.sub.78.5 Ti.sub.1.5 B.sub.17 Si.sub.3
               355     1.42    --      29.3   524
    Fe.sub.73 Hf.sub.3 B.sub.20 Si.sub.4
               354     1.28    --      19.3   587
    Fe.sub.73 Ta.sub.3 B.sub.20 Si.sub.4
               406     1.39    --      15.4   571
    ______________________________________


                                  TABLE VIII
    __________________________________________________________________________
    Examples of the 60 Hz magnetic properties of Fe.sub.100-
    .sub.a-b-c --M.sub.a --B.sub.b --Si.sub.c metallic glasses listed in
    Table VII.
    Samples were heat-treated at temperature T.sub.a for a hold-
    ing time t.sub.a in the presence of a longitudinal annealing
    field H.parallel.. Values of the dc coercive field H.sub.c and
    remanent inductions B.sub.r and 60 Hz properties of impedance
    permeability .mu..sub.z and core loss L at specified maximum
    induction level B.sub.m are given.
             T.sub.a
                t.sub.a
                  H.parallel.
                      B.sub.r
                         H.sub.c
                             L (mW/kg,
                                    .mu..sub.z
    Composition
             (.degree.C.)
                (h)
                  (A/m)
                      (T)
                         (A/m)
                             B.sub.m = 0.1 T)
                                    0.1 T
                                        0.5 T
    __________________________________________________________________________
    Fe.sub.78.5 Hf.sub.1.5 B.sub.17 Si.sub.3
             390
                1.5
                  1600
                      0.77
                         2.9 4.4    34,810
                                         88,060
    Fe.sub.78.5 Ti.sub.1.5 B.sub.17 Si.sub.3
             390
                1.5
                  1600
                      0.69
                         6.4 2.5    26,620
                                         49,460
    Fe.sub.73 Nb.sub.3 B.sub.20 Si.sub.4
             390
                1.5
                  1600
                      0.70
                         2.9 3.3    45,850
                                        102,970
    Fe.sub.73 V.sub.3 B.sub.20 Si.sub.4
             390
                1.0
                  1600
                      0.81
                         2.2 3.1    59,211
                                        148,401
    Fe.sub.78.5 W.sub.1.5 B.sub.17 Si.sub.3
             390
                1.0
                  1600
                      0.99
                         3.6 3.1    38,790
                                        106,670
    Fe.sub.78.5 Zr.sub.1.5 B.sub.17 Si.sub.3
             390
                1.0
                  1600
                      1.15
                         3.5 5.3    32,390
                                        106,330
    Fe.sub.73 Ta.sub.3 B.sub.20 Si.sub.4
             390
                1.0
                  1600
                      0.80
                         2.5 3.0    47,850
                                        119,670
    __________________________________________________________________________

Example 3

Fe-M-B-Si-C System

Ribbons having compositions given by Fe.sub.100-a-b-c-d M.sub.a -B.sub.b -Si.sub.c -C.sub.d and having dimensions about 0.5-5 cm wide and about 20 to 50 .mu.m thick were formed as in Example 1.

The magnetic and thermal data are summarized in Table IX below. The magnetic properties of these glassy alloys after annealing are presented in Table X.

The line frequency magnetic properties of these metallic glasses are comparable to those containing molybdenum (Example 1).

A combination of low ac core loss and high impedance permeability at line frequency is achieved in the metallic glasses of the present invention. The thermal stability is also shown to be excellent as evidenced by high crystallization temperature. These improved combination of properties of the metallic glasses of the present invention renders these compositions suitable for line frequency magnetic devices such as ground fault interrupters, current/potential transformers and the like.

                                      TABLE IX
    __________________________________________________________________________
    Examples of basic physical and magnetic properties
    of Fe--M--B--Si--C amorphous alloys where M = Cr or Mo. .theta..sub.f
    and T.sub.x1 are the ferromagnetic Curie and first crystalli-
    zation temperature, respectively. B.sub.s and .lambda..sub.s are the
    room temperature saturation induction and saturation
    magnetostriction, respectively.
    Composition
    Ex. No.
         Fe Cr
              Mo B  Si
                      C  .theta..sub.f (.degree.C.)
                             B/.sub.r (T)
                                 .lambda..sub.s (10.sup.-6)
                                      T.sub.x1 (.degree.C.)
    __________________________________________________________________________
     9   76 1.5
              1.5
                 17 4 -- 362 1.39
                                 15.6 535
    10   76 3 -- 17 2 2  324 1.36
                                 14.3 511
    11   76 --
              3  17 2 2  299 1.30
                                 17.3 535
    12   77 1.5
              -- 16 5 0.5
                         359 1.48
                                 25.1 523
    13   78 --
              2  13 6 1  324 1.36
                                 24.4 525
    14   78 2 -- 13 6 1  339 1.40
                                 21.4 514
    15   78 2 -- 12 7 1  331 1.37
                                 26.3 521
    16   78 2 -- 13.5
                    5.5
                      1  341 1.41
                                 22.7 509
    17   78 --
              2  12 7 1  336 1.35
                                 22.6 516
    18   76.75
            2 -- 16 5 0.25
                         352 1.46
                                 20.5 534
    __________________________________________________________________________


              TABLE X
    ______________________________________
    Examples of the 60 Hz magnetic properties of
    Fe.sub.100-a-b-c-d M.sub.a B.sub.b Si.sub.c C.sub.d metallic glasses,
    where M is one
    of molybdenum and chromium, listed in Table IX. Samples
    were annealed at temperature T.sub.a for a holding time t.sub.a in
    a 1600 A/m longitudinal field. Values of the dc coer-
    cive field H.sub.c and remanent induction B.sub.r and 60 Hz impe-
    dance permeability .mu..sub.z and core loss L at specified maxi-
    mum induction level B.sub.m are given.
                                   L
    Example
           T.sub.a
                  t.sub.a
                        B.sub.r
                             H.sub.c
                                   (mW/kg .mu..sub.z
    Number (.degree.C.)
                  (h)   (T)  (A/m) at 0.1 T)
                                          0.1 T  0.5 T
    ______________________________________
    12     400    1     1.19 1.1   2.5    80,470 210,830
    13     400    1     0.98 1.4   2.5    74,080 204,710
    14     400    1     1.01 2.8   5.0    35,570 116,810
    15     390    1.5   1.02 1.7   3.0    61,640 173,740
    16     400    1     1.17 2.5   4.9    38,680 129,500
    ______________________________________


              TABLE XI
    ______________________________________
    Magnetic properties of the metallic glass
    Fe.sub.76.75 Cr.sub.2 B.sub.16 Si.sub.5 C.sub.0.25 heat-treated at
    temperature T.sub.a for
    a holding time t.sub.a in the presence of various longitu-
    dinal magnetic fields. Toroids were cooled to room tem-
    perature at a rate -3.degree. C./min. following the heat-treat-
    ment. Core loss (L) and impedance permeability (.mu..sub.z)
    were measured using sinusoidal field excitation at 60 Hz
    to a maximum induction B.sub.m as indicated.
    ______________________________________
    Example T.sub.a t.sub.a Annealing H.sub.c
                                             B.sub.r
    Number  (.degree.C.)
                    (h)     Field (A/m)
                                      (A/m)  (T)
    ______________________________________
    1       400     1         800     0.87   1.26
    2       420     1         800     1.3    1.19
    3       380     1         800     1.2    1.13
    4       400     1       2,400     --     --
    5       400     0.25      800     --     --
    6       400     2         800     --     --
    7       400     1       4,000     0.58   1.29
    8       400     1         200     0.73   1.25
    ______________________________________
            L (mW/kg,
                     .mu..sub.z
    Example   B.sub.m = 0.1 T)
                         0.1 T     0.4 T 0.6 T
    ______________________________________
    1         1.4        143,080   259,220
                                         293,850
    2         2.9         73,250   182,550
                                         227,110
    3         2.0         92,990   212,500
                                         259,330
    4         1.6        127,180   221,070
                                         --
    5         2.5         86,860   --    --
    6         2.0         93,830   --    --
    7         3.2         64,550   --    --
    8         1.5        133,400   268,560
                                         --
    ______________________________________

The magnetic properties of these glassy alloys after annealing in a longitudinal applied field are presented in Table X. Various annealing conditions for the metallic glass Fe.sub.76.75 Cr.sub.2 B.sub.16 Si.sub.5 C.sub.0.25 and the obtained results are summarized in Table XI. Frequency dependence of permeability of this optimally annealed alloy is listed in Table XII.

Table XIII lists magnetic properties of the metallic glass alloy Fe.sub.76.75 Cr.sub.2 B.sub.16 Si.sub.5 C.sub.0.25 heated to 400.degree. C., held for 1 h, and cooled below 200.degree. C. at various rates, all in the presence of a 1600 A/m longitudinal field. Values of dc remanent induction (B.sub.r), dc coercive field (H.sub.c) and 60 Hz core loss (L) and impedance permeability (.mu..sub.z) are shown for a maximum induction (B.sub.m). The best properties are seen to have resulted from cooling rates of -0.5.degree. C./min to -10.degree. C./min.

                  TABLE XIII
    ______________________________________
                              L
    Average Cooling
               B.sub.r
                      H.sub.c (mW/kg)  .mu..sub.z
    Rate (.degree.C./min)
               (T)    (A/m)   (Bm = 0.1 T)
                                       0.1 T 0.5 T
    ______________________________________
      -1       1.29   0.73    1.5      138,250
                                             285,480
      -3       1.26   0.87    1.4      143,080
                                             276,535
     -10       1.26   0.73    1.4      141,880
                                             288,920
    -1000*     0.59   2.8     1.7       95,810
                                             223,570
    ______________________________________
     *Quenched in water

The presence of chromium or molybdenum is seen to increase the permeability and the crystallization temperature and to lower the ac core loss, exciting power and magnetostriction. Especially noted is the fact that the optimally heat-treated metallic glass Fe.sub.76.75 Cr.sub.2 B.sub.16 Si.sub.5 C.sub.0.25 of the present invention has a coercivity of 0.5 A/m and has a low core loss of 1.4 mW/kg and impedance permeability of 300,000 at 60 Hz and at the induction level of 0.6 Tesla. The combination of these properties make these compositions suitable for line frequency devices such as ground fault interrupters and current transformers.

                  TABLE XII
    ______________________________________
    Frequency dependence of impedance permeability .mu..sub.z
    of metallic glass Fe.sub.76.75 Cr.sub.2 B.sub.16 Si.sub.5 C.sub.0.25
    annealed for 1 h
    at 400.degree. C. with an 800 A/m longitudinal field.
    f (H.sub.z)    0.1 (T) 0.6 (T)
    ______________________________________
     50            182,290 459,370
     100           151,080 319,430
     200           117,700 207,830
     500            72,820 108,500
    1000            47,330  62,390
    2000            31,00   38,550
    ______________________________________


              TABLE XV
    ______________________________________
    Field dependence of the 60 Hz impedance permeabi-
    lity of metallic glass Fe.sub.76.75 Cr.sub.2 B.sub.16 Si.sub.5 Co.sub..25
    annealed for
    1 h at 400.degree. C. with transverse and longitudinal fields of
    8000 and 1600 A/m, respectively, showing peak applied 60
    Hz magnetic field H.sub.m, impedance permeability .mu..sub.z, and
    maximum induction B.sub.m.
    H.sub.m (A/m)  .mu..sub.z
                           B.sub.m (Tesla)
    ______________________________________
    0.226           19,080 0.005
    0.394           45,030 0.002
    0.566           66,070 0.047
    1.131          107,670 0.135
    2.263          129,710 0.369
    3.394          126,670 0.540
    4.525          117,890 0.670
    5.657          109,490 0.778
    6.788          102,230 0.872
    ______________________________________

Table XIV shows magnetic properties of the metallic glass Fe.sub.76.75 Cr.sub.2 B.sub.16 Si.sub.5 C.sub.0.25 annealed in the presence of various transverse magnetic fields. Table XV shows the detailed field dependence of impedance permeability of optimally transversely annealed Fe.sub.76.75 Cr.sub.2 B.sub.16 Si.sub.5 C.sub.0.25. That permeability is at least 40,000, and varies by no more than a factor of three for applied fields ranging from 0.4 to 10.0 A/m. The resulting material is especially suited for line frequency current/potential transformers in which the near-constant permeability renders the output nearly linearly over a wide range of applied fields.

                  TABLE XIV
    ______________________________________
    Magnetic properties of the metallic glass
    Fe.sub.76.75 Cr.sub.2 B.sub.16 Si.sub.5 C.sub.0.25 heat-treated at
    temperature T.sub.a for
    a holding time t.sub.a in the presence of various transverse
    (H.perp.) and, optionally, longitudinal (H.parallel.) magnetic
    fields. Toroids were cooled to room temperature at
    about -3.degree. C./min. following the heat treatment. Coer-
    civity (H.sub.c) and remanent induction (B.sub.r) were measured
    from dc BH loops. Core loss (L) and impedance perme-
    ability (.mu..sub.z) were measured using sinusoidal field
    excitation at 60 Hz to a maximum induction B.sub.m as
    indicated.
    ______________________________________
    Example
           T.sub.a
                  t.sub.a
                         Annealing Field
                                       H.sub.c
                                              B.sub.r
    Number (.degree.C.)
                  (h)    H.parallel. (A/m)
                                 H.perp. (A/m)
                                         (A/m)  (T)
    ______________________________________
    16     425    2      1,600   8,000   3.2    0.56
    17     415    2      1,600   8,000   1.7    0.31
    18     400    2      1,600   8,000   1.3    0.23
    19     385    2      1,600   8,000   1.4    0.31
    20     400    1        800   16,000  1.0    0.30
    21     400    1        240   8,000   1.1    0.36
    22     400    1      1,600   8,000   0.87   0.20
    23     400    1        800   8,000   1.0    0.21
    24     400    1        800   4,000   0.87   0.30
    25     400    1         0    4,000   1.0    0.85
    26     400    1         0    2,400   1.0    0.93
    27     400    1         0      800   0.80   1.04
    28     400    1         0    8,000   1.3    0.53
    29     400    1        800     800   0.58   0.51
    30     400    1      2,400   8,000   1.5    0.23
    31     400    1         0    16,000  --     --
    ______________________________________
    Example   L (mW/kg)  .mu..sub.z
    Number    (B.sub.m = 0.1 T)
                         0.1 T     0.4 T 0.6 T
    ______________________________________
    16        4.3         34,850    73,600
                                          79,080
    17        2.7         50,060    87,780
                                          87,210
    18        1.9         63,570    97,920
                                         127,380
    19        1.4         69,390    97,170
                                          93,070
    20        1.5         62,600    76,490
                                          68,170
    21        1.4        152,220   100,910
                                          89,728
    22        1.2         97,850   135,540
                                         129,925
    23        1.3         74,870   101,700
                                         100,510
    24        1.2        115,815   178,640
                                         188,420
    25        1.8         98,590   191,300
                                         211,120
    26        1.6        115,260   242,370
                                         278,340
    27        1.8         82,680   124,630
                                         102,490
    28        1.4        141,530   267,840
                                         305,870
    29        1.4        122,690   215,880
                                         236,660
    30        1.5         61,190    73,870
                                         --
    31        2.1         70,274    92,080
                                         --
    ______________________________________

Having thus described the invention in rather full detail, it will be understood that this detail need not be strictly adhered to but that various changes and modifications may suggest themselves to one skilled in the art, all falling within the scope of the present invention as defined by the subjoined claims.

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Current U.S. Class:	148/304; 420/64; 420/67; 420/117; 420/121; 420/123
Intern'l Class:	H01F 001/04
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